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Additive Manufacturing (AM) of refractory materials necessitates either a substantial laser power or the utilization of various easily fusible binders. In this study, we present an alternative approach involving the utilization of spherical reactive composite particles composed of Ti and Al. These particles are acquired through high-energy ball milling prior to use. Employing these powders, we achieved the production of hightemperature TiAl-based materials through the Selective Laser Melting (SLM) technique. Upon laser heating, the composite particles, which have been mechanically activated, swiftly undergo a reactive process, liberating a substantial amount of heat and transforming into corresponding intermetallic compounds. The ignition of this combustion reaction can be initiated at relatively low temperatures, and the exothermic effect serves to prevent abrupt cooling of the tracks formed during sintering. This methodology enables the creation of dense intermetallic materials possessing a uniform structure in a single step via SLM, obviating the requirement for high-powered lasers, binders, or supplementary post-processing and heat treatments.
